Wall system fastener with seal member

ABSTRACT

A wall fastener assembly for use with a building wall system, with the wall fastener assembly including a fastener and an elongated, semi-rigid seal member. The fastener includes a shaft and a head, with the fastener configured to be secured to the wall system. The seal member includes opposed first and second ends, and a center bore that extends along the length of the seal member and is configured to receive the shaft of fastener. When the fastener is secured to the wall system the first end of the seal member is configured to compress against a portion of the wall system to form a first seal and the opposite second end of the seal member is configured to form a second seal to thereby seal the wall fastener assembly against the wall system.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority of U.S. provisional applicationSer. No. 62/838,425 filed Apr. 25, 2019, and U.S. patent applicationSer. No. 16/661,438 filed Oct. 23, 2019, which are both herebyincorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention is directed to wall system fasteners, and inparticular, toward energy efficient fasteners with seals that may beused for various applications, including for sealed securing of brick orother masonry veneers, exterior wall treatments, insulation attachments,or cladding or girt attachments, such as to insulated cavity walls.

BACKGROUND OF THE INVENTION

Fasteners are used in building construction of wall systems, includingfor use in securing insulation over air, water, and/or vapor barriers,including threaded fasteners, such as screws, and non-threadedfasteners, such as nails. Threaded fasteners are also used withconventional brick or masonry anchors, such as for insulated cavitywalls, such as in buildings utilizing veneer brick or masonry walls orinsulated rainscreen walls.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide a variety of air, fluid,weather, and/or vapor sealing wall fasteners for securing or retainingcomponents or materials to a wall system, such as layer of continuousinsulation or fluid barrier and/or cladding systems. These wallfasteners include a vapor or fluid seal to provide several uniquebenefits. Exemplary embodiments provide a fluid or vapor barrier seal,such that fluid or vapor leakage between the fastener and a layerinsulation, an air-barrier, a weather barrier, or wall substrate, isreduced or eliminated, thereby reducing damage and energy transferthrough the insulation, barrier, or substrate positioned between anexterior wall treatment or cladding and an vapor or fluid barriercovered inner wall. Fluid barrier performance is also improved when thebase of the fluid barrier seal compresses against the fluid barriermaterial. Furthermore, large diameter washers may be configured to affixto the insulation and may also compress the fluid seal with theinsulation at the point of fastener penetration, and thus effectivelyprovide a “gasket” against air and water leakage.

In one form of the present invention, a wall system fastener is providedfor retaining insulation includes a mechanical fastener, such as anelongated screw, and a tube seal or gasket. The screw may be configuredto secure a layer of insulation to the wall. The tube seal is configuredto provide a fluid or vapor barrier between the layer of insulation andthe screw. Preferably, the tube seal compresses against a layer of vaporbarrier disposed with the wall system to further seal between the wallfastener and the wall system. The wall system fastener may include awasher that is configured with a central portion comprising a centerhole configured for receiving the screw. The washer's central portion isconfigured for compressively mating with the tube seal to effectivelyseal the interaction point between the seal and the washer.

In another form of the present invention, a wall anchor is provided forretaining a masonry or brick veneer alongside a wall includes anelongated tubular shank, a tube seal or gasket, and a washer. The shankis configured to provide a space for a layer of insulation between thebrick veneer and the wall. The shank comprises a center bore runningdown the length of the shank and is configured for receiving a screwthrough the bore for securing the wall anchor to the wall. The shankalso includes a pair of flanges positioned on a proximal ornon-penetrating end of the shank. The pair of flanges are configured toform a groove between them. The tube seal is configured to provide afluid or vapor barrier between the layer of insulation, the shank, andthe washer. Preferably, the tube seal compresses against a layer ofvapor barrier disposed with the wall system to further seal between theanchor and the wall system. The washer is configured with a centralportion comprising a center hole configured for receiving the shank. Thewasher's central portion is configured for supporting the pair offlanges when the screw is inserted into the wall. The washer's centralportion is configured for compressively mating with the tube seal toeffectively seal the interaction point between the seal and the washer.Optionally, the wall anchor further includes an angled wire tieinstalled on the anchor to secure the veneer to the wall system. Theangled wire tie includes a narrow portion configured to be retained bythe groove. The angled wire tie is configured for inserting between rowsof masonry of the brick, masonry, or stone veneer.

In one aspect, the length of the tube seal is chosen to be substantiallyequal to the thickness of the insulation such that the tube sealcompresses against the substrate beneath the insulation. In anotheraspect, the length of the shank is chosen to be substantially equal tothe thickness of the insulation such that the shank compresses againstthe substrate beneath the insulation. In yet another aspect, the lengthof the shank is chosen to be equal to the combined thickness of theinsulation and a wall board, such as gypsum sheathing, such that theshank passes through the wall board. When the length of the shank equalsthe thickness of the insulation and the wall board, the length of thetube seal is substantially equal to the thickness of only theinsulation, such that the tube seal does not pass through the wall boardand compresses against the vapor, weather, and/or fluid barrier on thesurface of the wall board.

In one aspect of the present invention, the tube seal comprises anon-metallic material, and may be configured as a resilient and flexiblematerial configured to compress between the anchor and the insulation.In the case of a resilient and flexible tube seal, the material may bepolyvinyl chloride, polyurethane, or similar semi-rigid and resilientpolymer or co-polymer. The tube seal may be formed from injection moldedpolymers or from extruded polymer tubing. The tube seal comprises acenter bore running down the length of the tube and is configured forreceiving the screw or the shank of the anchor through the bore.

In one aspect of the present invention, the tube seal includes aconical, funnel, or bugle tip at one of its ends that providesadditional surface area to seal the interaction point between the washerand the seal. Optionally, fins, ribs, or supports are formed along thetube seal to rotationally engage the tube seal with the insulation toreduce spinning of the tube seal during installation of the anchorthrough the insulation. In one aspect, the tube seal includes a taperedor pointed tip at an end opposite the washer to provide reducedobstruction on the tube seal as it passes through the insulation duringinstallation.

Thus, masonry veneers, insulation attachments, or cladding or girtattachments may be retained by the wall fasteners of the presentinvention, such as retaining a layer of insulation is to a wall. Thewall fasteners provide improved thermal insulation by resisting fluidand vapor flow between the fastener and the insulation or wall material.The wall fasteners may be used to secure various types of wallcomponents, treatments, or veneers to a wall system, including wallsystems having rigid or flexible insulation, vapor, fluid, and/orweather barriers, wall boards, or the like.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a wall fastener assembly with tube sealin accordance with an aspect of the present invention;

FIG. 1A is a perspective view of the tube seal removed from the wallfastener assembly of FIG. 1 ;

FIG. 2 is a perspective view of the wall fastener of FIG. 1 disposed insealing contact with a barrier layer configured as a fluid, vapor,and/or weather barrier;

FIG. 3 is a partial sectional perspective view of the wall fastener ofFIG. 1 , with the fastener disposed in a section of a wall system;

FIG. 4 is a perspective view of another embodiment of a wall fastenerconfigured as a wall anchor with tube seal in accordance with anotheraspect of the present invention;

FIG. 5 is an exploded perspective view of the wall anchor of FIG. 4 ;

FIG. 6 is a perspective view of the wall fastener of FIG. 4 , with thewall fastener disposed in a wall system;

FIG. 7 is a partial sectional perspective view of the wall fastener ofFIG. 1 depicting a compressed tube seal;

FIG. 8 is a perspective view of a flanged, conical, funnel, or bugle endseal for wall fasteners in accordance with the present invention;

FIG. 9 is a perspective view of a wall system having a hat channelfastened to a section of insulation with a wall fastener with a tubeseal in accordance with a further aspect of the present invention;

FIG. 10 is an exploded perspective view of the hat channel and wallfastener of FIG. 9 ;

FIGS. 11A-11B are cross sectional side views of the wall fastener andhat channel of FIG. 9 depicting a sequence of installation of the wallfastener; and

FIG. 12 is a partial sectional perspective view of a wall systemincluding the wall fastener of FIG. 1 and the wall fastener and hatchannel of FIG. 9 .

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings and the illustrative embodiments depictedtherein, an exemplary wall fastener or fastener system with tube seal ortube gasket may be implemented in any one or more of the illustrativeembodiments discussed herein. The wall fasteners with tube seal of thepresent invention can provide for a variety of improvements andbenefits. For example, leakage prevention performance is improvedbecause the base of an exemplary tube seal or gasket compresses on abarrier material disposed behind insulation. The tube seal also providesa thermal break or disruption of thermal transmission through themetallic components of a wall system and the wall fastener. Furthermore,as described herein, the wall fasteners may include exemplary largediameter washers that are configured to compress the tube seal or gasketseal to further inhibit leakage at the interface with the washer. Noadditional sealing of the fasteners is required before, during, or afterinstallation of the wall fastener with tube seal, thereby reducingbuilding costs, improving efficiency of construction, and increasingsustainability of a building envelope. While the wall fastener with tubeseal is particularly useful for securing insulation to a wall systemhaving a fluid barrier, the wall fastener with tube seal may be adaptedfor use with various wall systems, wall system components, claddingsystems, material types, and fastener arrangements, such asstucco/plaster, masonry, cladding channels, brick anchors, and brickties, for example.

Referring to FIGS. 1-3 , an exemplary wall fastener or fastener assembly10 including a fluid or tube seal or gasket member 12 is illustrated foruse in retaining a wall system component, such as a layer of insulation14 or other wall system material commonly installed in building walls.As shown in the illustrated wall system configuration embodiment of FIG.3 , the wall fastener 10 is configured for retaining a layer ofinsulation 14 to an inner wall that is covered with a barrier layer 16,such as an air or fluid barrier, and provides a fluid seal between thefastener 10, insulation 14 and barrier 16. In particular, one end 13 aof seal member 12 seals against the underside of the washer 22 while theopposite end 13 b of seal member 12 seals against the barrier layer 16,with the head 20 a of fastener 20 sealing against the opposite side ofwasher 22 from end 13 a. Fastener assembly 10 thereby secures insulationlayer 14 in place while inhibiting fluid and/or air from penetratingbeyond barrier layer 16 to thereby provides both a vapor and thermalbarrier, despite fastener 20 piercing through barrier layer 14 duringassembly, and may be employed not only for securing insulation, but alsofor use with various wall systems, including cladding support systemssuch as channels or brackets for mounting cladding, including for vinylsiding, lathe applications, and the like.

The insulation layer 14 may be one of various types of insulation, suchas a rigid or semi-rigid, batt or matt type of insulation, includingextruded polystyrene (XPS), expanded polystyrene (EPS), polyisocyanurate(polyiso), mineral wool, or other type of insulation. The barrier layer16 may be one of various types of fluid and/or air barriers, includingfluid applied, peel-and-stick adhered membrane, sheet-applied membrane,or weather resistant barrier (WRB) panel. Such inner wall assemblies maybe formed from one or more of steel or wooden studs or framing members18, along with masonry, plywood sheathing, or gypsum sheathing overlays26. As illustrated in FIG. 3 , wall fastener assembly 10 with washer 22retains insulation layer 14 in place, with seal 12 inhibiting air and/orfluid from passing beyond barrier layer 16, and with seal 12 controllingthe depth to which fastener 20 penetrates into the wall assembly viaseal 12 contacting barrier layer 16, which in turn is disposed againstthe rigid sheathing overlay 26. As further understood from theembodiment illustrated in FIG. 3 , fastener 20 penetrates throughsheathing overlay 26 and into stud 18.

The tube seal 12 is formed from a non-metallic material, such as in oneembodiment a semi-rigid material, such as flexible polyvinyl chloride, apolyurethane, or a similar polymer or co-polymer. Seal 12 in theillustrated embodiment is an ether based polyurethane material.Optionally, the tube seal 12 may be injection molded or extruded andinclude properties such as UV inhibition, high and low temperatureresiliency, and compression resiliency. The seal 12 is sufficientlyrigid or stiff so as to burrow or press through the insulation 14 as thefastener 10 is being installed, without the need to pre-drill a holethrough the insulation 14 and without substantial deformation orcollapsing of the seal 14 until the seal contacts the barrier layer 16that is supported against the sheathing overlay 26, and is compliable soas to slightly compress during installation. That is, upon fastener 20penetrating the wall assembly sufficient such that the seal 12 isslightly compressed between the underside of washer 22 and againstbarrier layer 16 supported on sheathing overlay 26, seal 12 willslightly compress but inhibit fastener 20 from penetrating further intowall assembly when being torqued at a reasonable value by increasing theresistance to further torquing. Alternatively, a tube seal for use inparticular implementations of the present invention may be a rigidplastic, with the tube seal still being operable to provide a seal ateither end.

In the embodiment of FIGS. 1-3 , seal 12 is substantially tubular orcylindrical in shape, with an elongate length or body relative to itscircular cross section. As best illustrated in FIGS. 1, 1A, and 2 , thefluid seal 12 includes a center bore 15 running down the length of theseal 12 whereby seal 12 has a wall thickness defined by its outsidediameter and the inside diameter of bore 15. Bore 15 is configured forreceiving an elongate mechanical fastener, such as a threaded fasteneror screw 20, where fastener 20 includes a shaft 21 that is longer thanthe length of seal 12. Various forms of fasteners may be used inconnection with the present invention, including fasteners of differinglengths, diameters, pitches, head formats and styles. While theillustrated embodiments depict a threaded fastener, the tube seal 12 maybe disposed on a non-threaded fastener, such as a nail or pin which maybe hammered manually or shot automatically through bore 15 and into thewall system. In the illustrated embodiment, the wall fastener assembly10 also includes a washer 22 with a raised annular ridge or rim portion24 surrounding a central annular region configured to receive the screw20.

As illustrated in FIG. 2 , when the screw 20 of the wall fastener 10 istightened, the bottom end 13 b of the tube seal 12 compresses on thebarrier layer 16 to effectively seal the penetration of the screw 20through the barrier layer 16 and thereby inhibit air and water fromentering bore 15 at end 13 b. At the same time, the top end 13 a of thetube seal 12 compresses on the underside of the washer 22 to effectivelyseal against the washer 22 to thereby inhibit air and water fromentering bore 15 at end 13 a. The underside of the washer 22 includes acentral flat surface against which the tube seal 12 compresses. Thefriction created as the fastener 20 is tightened and the tube seal 12 iscompressed between the barrier 16 and the washer 22 limits or stops thetube seal 12 from spinning. The screw 20 may continue to be tightenedfurther once the seal 12 is no longer spinning, or at least spinningless than the rotation of the fastener 20 itself. The limiting orstopping of the spinning of the tube seal 12 minimizes or eliminatesfrictional damage to the insulation 14, and in particular minimizesfriction and damage to the barrier layer 16 as the wall fastener 10 isinstalled. That is, barrier layer 16 may be a membrane or filmsusceptible to tearing. Accordingly, the limiting of the rotation of thetube seal 12 when in contact with the barrier layer 16 aids inpreventing such damage, where a seal that is integral with the rotatingfastener will tend to burrow/burn through the barrier layer 16. Becausethe exemplary tube seal 12 compresses on the barrier layer 16 materialand seals the penetration point in the barrier layer 16, the barrier'sperformance will be improved.

When the wall fastener assembly 10 with the seal 12 is installed througha section of insulation 14, the assembly 10 supports the insulationlayer 14 and seal 12 prevents leakage in and around insulation 14 fromentering the wall fastener assembly 10. Once the screw 20 has beendriven through the barrier layer 16 and into the substrate, the drivenside of the screw head 20 a will be tightly pressed against the washer22, and effectively seal against air and water penetrating at the screw20 and washer 22 interface, in particular between the screw head 20 aand washer 22 and between the end 13 a of seal 12 and bottom side ofwasher 22.

Washer 22 includes an upper surface and a lower surface, with the uppersurface including a chamfered or angled opening disposed about thethrough hole in washer 22, where the chamfered opening is configured toreceive screw head 20 a, and where the underside of screw head 20 acorrespondingly is angled such that screw head 20 a is able to seatwithin the chamfered opening to thereby form a seal there against. Inparticular, washer 22 may be constructed in accordance with the washersdisclosed in U.S. Pat. No. 9,309,915, which is incorporated herein byreference in its entirety. Accordingly, optionally as shown in theillustrated embodiment of FIG. 1 , the washer 22 may be constructed of aplastic material and include prongs or spiked projections 22 aconfigured to grab or bite into the insulation 14 to reduce spinning ofthe washer 22 during installation. It should be appreciated, however,that numerous alternative forms of washers may be employed with thepresent invention, including depending on the type of wall assemblybeing constructed. For example, plastic washers without prongs may beused, including plastic washers with alternative configurations,including in constructions in which a barrier layer 16 is employed.Still further, washers constructed of metal may be employed. Withoutlimitation, washers that may be used in connection with the presentinvention includes washers provided by Rodenhouse Inc. of Grand Rapids,Mich., including THERMAL-GRIP, PLASTI-GRIP, and GRIP-PLATE brandwashers.

In the illustrated embodiment of FIGS. 4-6 , an alternative wallfastener assembly configured as a wall anchor 110 includes a shank 112with a tube seal 114 disposed on the shank 112. The shank 112 includes apair of generally disc-like flanges 116 disposed on a proximal ornon-penetrating end of the shank 112 and forming an annular groove 118therebetween. An exemplary shank 112 is described in commonly assignedU.S. patent application Ser. No. 16/661,438 filed Oct. 23, 2019, whichis hereby incorporated herein by reference in its entirety. The shank112 may be formed of resinous plastic with an elongated tubularconstruction, with a center bore running down the length of the shank112 and configured for receiving a large diameter flat head mechanicalfastener, such as a threaded fastener or screw 120 (FIGS. 4-5 ). Thewall anchor 110 includes a washer 122 similar to the washer ofembodiment 10, however washer 122 has a larger opening diameterconfigured for receiving the shank 112 and includes an annular raisedrim 124 configured to receive a flange 116 of the shank 112. The washer122 includes spiked projection 122 a to secure the washer 122 into theinsulation 14. Optionally, an alternative wall anchor replaces thewasher with a large diameter disc-like flange that takes the place ofthe inner flange 116 formed on the shank 112. The optional largediameter flange takes the place of the washer 122 and performssubstantially the same function.

As illustrated in FIG. 6 , the wall anchor 110 is depicted installed ina wall system with an insulation layer omitted to illustrate how theshank 112 and fluid seal 114 of the wall anchor 110 butt up against theair barrier 16 covering the wall. A partial sectional illustration ofthe wall anchor installed through an insulation layer 14 is depicted inFIG. 7 . The fluid seal 114 may be shorter than the shank 112 such thatthe fluid seal 114 butts up against the air barrier 16 with the shank112 continuing through the air barrier 16 and wall board or gypsum 26 tobottom out on the stud 18. The length of the shank 112 and seal 114 maybe selected to match a thickness of insulation 14 and wall board orgypsum 26. When the length of the seal 114 matches the insulation 14thickness, the seal 114 will “bottom out” on the surface of the barrierlayer 16 covering the wall. By “bottoming out” the seal 114 on thesurface of the air barrier 16, the hole created by the screw 120 when itpasses through the air barrier 16 will be covered by the bottom of thetube seal 114, and the hole created by the shank 112 through the wallboard will also be covered by the seal 114. As best illustrated in FIG.6 , when the screw 120 of the wall anchor 110 is tightened, the bottomof the tube seal 114 compresses on the air barrier 16 to effectivelyseal the penetration against air and water.

As illustrated in FIG. 6 , the wall includes studs 18 and an overlayerof exterior gypsum sheathing 26. While the illustrated embodimentincludes studs 18 and gypsum sheathing 26, the wall anchor may beutilized with various types of wall systems, such as having a layer ofinsulation and a layer of air-barrier mounted to the face of a masonrywall. Optionally, in scenarios where a layer of gypsum sheathing 26 isdisposed between the studs 18 and the air barrier 16, the tube seal 114may be shorter than the length of the shank 112 by a distance that issubstantially equal to the thickness of the gypsum sheathing 26 (FIG. 4). In this optional embodiment, the rigid barrel of the shank 112 cutsthrough and extends through the layer of gypsum sheathing 26 to bottomout on the stud 18, while the seal tube 114 compresses against the faceof the air barrier 16, as well as the underside of the washer 122. Thisensures an air and water tight seal between the anchor 110 and the wallsystem and its various components. Although illustrated with aparticular configuration of brick anchor or wall anchor 110, it shouldbe appreciated that the present invention may be employed withalternatively configured such anchors, including brick or wall anchorsproduced by various manufacturers. In such embodiments tube seal 114 isdisposed over the shank of the wall anchor to provide a seal against abarrier layer at one end and against a washer portion of the wall anchorat the opposite end.

Referring to FIG. 8 , an alternative tube seal 212 may include a flangedor conical or funnel or bugle end 28. The bugle end 28 providesincreased surface area to ensure effective sealing between the tube seal212 and either the washer 22 or the screw head 20 a. The tube seal 212of FIG. 8 may be configured for use with wall anchor 110 as well.Optionally, outwardly extending ridges 30 along the barrel of the tubeseal 212 are provided to reduce the incidence of seal rotation duringinstallation while the threaded fastener 20 is being driven, which mayreduce damage to the insulation 14 and/or barrier layer 16 material.Optionally, the barrier layer 16 end of the tube seal 212 includes apointed or tapered tip 32 to assist the tube 212 in passing through alayer of foam insulation 14. In the illustrated embodiment the end 28 isshown as being angled. In an alternative arrangement, however, a tubeseal having a flanged end may be angled such as at a ninety-degreeangle. In such an arrangement the underside of the flange isperpendicular to the elongate length of the tube seal, and the upperside of the flange is generally parallel with the underside of theflange. Such a flanged end may be employed with any of the tube seals asdisclosed herein.

Referring to FIGS. 9-12 , and the embodiments illustrated therein, awall fastener assembly 210, similar to fastener assembly 10 isillustrated in connection with a channel or bracket for mountingcladding systems, such as for vinyl siding, lathe applications, or thelike. In the illustrated embodiment a hat channel 34 is assembled to awall system on the exterior side of a layer of insulation 14, such asmay be used for securing a cladding channel or girt system. The wallfastener 210 includes a tube seal or gasket 212 similar to tube seal 12.The tube seal 212 is configured to receive an elongate mechanicalfastener, such as a threaded fastener or screw 214 through a centralbore through the tube seal 212. The hat channel 34 includes a pair ofmounting flanges or portions 36 that are configured to mountsubstantially flat along the face of the insulation layer 14. Themounting flanges 36 include a plurality of holes 38 spaced uniformlyalong the length of the flanges 36 to provide locations for receivingthe fastener assemblies 210 for securing to the wall assembly. Theelongate outer edges of the flanges 36 may be chamfered, rounded oreased so as to inhibit tearing of insulation layer 14. The hat channel34 additionally includes a plurality of holes 39 along the elongate legs40 that provide locations for drainage or ventilation as necessary. Forexample, the holes 38 may be uniformly spaced at one inch (1″) intervalsalong the flange 36. The hat channel 34 provides a location at whichadditional cladding or building materials can be secured to the wallsystem, such as to elongate face 41 of channel 34, or to legs 40.

The tube seal 212, as best illustrated in FIGS. 11A-11B, has an outerdiameter that is somewhat smaller than the diameter of holes 38 suchthat the tube seal may freely pass through the holes 38 while installingthe wall fastener 210 through the hat channel 34, as sequentiallydepicted in FIGS. 11A-11B. The seal 212 has a length that is somewhatlonger than the thickness of the insulation layer 14. For example, theseal 212 may be one-eighth of an inch (⅛″) longer per inch of insulationthickness provided, e.g. for a two inch (2″) thick insulation layer, theseal 212 length would be two and one-quarter inch (2.25″). As such, whenthe screw 214 is tightened into the wall system, such as through abarrier layer 16, a layer of gypsum sheathing 26 and into a stud (notshown in FIGS. 11A and 11B), the tube seal 212 contacts or “bottoms out”against the barrier layer 16 (FIG. 11B). When the end 113 b of seal 212contacts the barrier layer 16, a portion of the seal 212 at end 113 aremains and extends beyond the face of the insulation 14 and the flange36 of the hat channel 34. As the screw 214 is tightened further, theseal 212 is compressed between the head of the screw 216 and the fluidbarrier 16 and gypsum sheathing 26 (FIG. 11B). As such, the fluidbarrier end 113 b of the seal 212 forms a seal with the fluid barrier16. And, as the seal 212 is compressed, the seal end 113 a expandsand/or conforms to the taper or form of the underside of the screw head216 and forms a seal between the flange 36 and the screw 214.Optionally, the seal 212 may include a pre-formed tapered end 212 a (seeFIG. 10 ) configured to receive and seal against the screw head 216,similar to the seal 12 shown in FIG. 8 . The portion of the seal 212that is compressed between the screw head 216 and the flange 36 providesa thermal break or interruption of thermal transfer between the metallicmaterials of the screw 214 and hat channel 34 thereby reducing energycosts associated with the wall system. Although FIGS. 9-11B illustratechannel 34 being installed in a horizontal manner, it should beappreciated that channel 34 may alternatively be mounted in a verticalmanner. In such an arrangement, due to the narrow width of the verticalstuds, mounting holes 38 a may be applied to face 41, such as forexample spaced six inches apart. A fastener assembly 210 is then appliedthrough face 41. As shown in FIG. 11B in dashed lines, such analternative fastener assembly 210 includes a longer fastener and tubeseal such that the tube seal extends beyond the surface of theinsulation layer 14 such as, for example but not limited to, by around0.875 to 1.5 inches.

It should also be appreciated that alternative channels or brackets maybe employed, as well as alternative fastener assemblies, including foralternative cladding systems. For example, although channel 34 is shownas a hat channel having two flanges 36, alternative channels or bracketsmay be C-shaped and/or include one or more than two mounting flanges.Moreover, in the case of a vinyl siding assembly, a fastener configuredas a roofing style nail having a flat head may be employed wherein thetube seal passes through a mounting opening in the upper flange of thevinyl siding panel, with the underside of the flat head nail sealingdirectly against the tube seal. Likewise, a flat head nail may be usedwith securing lathe, and a nail gun may be used for applying nails invinyl siding, lathe or other such cladding configurations. Stillfurther, in further embodiments a washer, such as either a plastic ormetallic washer may be utilized with a bracket or channel for a claddingsystem. Alternatively, the fastener for use with the tube seal mayinclude a bonded gasket, such as disposed beneath the head of thefastener, with the gasket then compressing against the end of the tubeseal. Moreover, in selected embodiments the tube seal is slightly longerthan the thickness of the insulation layer, as discussed above. Inalternative embodiments, the tube seal may be equal to the width of theinsulation layer. Still further, in particular embodiments when employedwith a washer, the washer may include a central extending portion on theunderside of the washer against which the tube seal end engages. In sucha case, the extending portion of the washer may be recessed below thesurface of the insulation layer, in which case the tube seal would beconstructed to be slightly less than the thickness of the insulationlayer. Accordingly, as intended herein, unless specifically stated, atube seal that has a length that is approximately equal to the width ofthe insulation layer means that the tube seal may be slightly longer,such as by about 0.125 inches for every inch of thickness of insulation,or is equal to the thickness of the insulation, or is shorter than thethickness of the insulation based on the engagement with the undersideof a washer for use with the tube seal.

Accordingly, the wall fastener with tube seal provides a cost and energyefficient fastener for securing wall system components, such as vaporbarriers, layers of insulation, and cladding channels to a wall. Thefastener with tube seal secures the component or material the wall andforms a seal at the penetration(s) made by the fastener through thecomponent or material to seal against air, liquid, or other fluids fromleaking through the penetrations. The wall fastener may include aswasher and/or flared or contoured ends on the tube seal to facilitatetight seals at the penetrations. The tube seal may be configured toreceive a screw or a rigid shank that is further configured to receivethe screw. A washer may be provided with the wall fastener to provideadditional seal as necessary depending on the material which the wallfastener is securing and retaining on the wall. The tube seal alsoprovides a thermal break or interruption in thermal transmission whendisposed between metallic components of the wall fastener or wallsystem.

Changes and modifications in the specifically described embodiments canbe carried out without departing from the principles of the presentinvention which is intended to be limited only by the scope of theappended claims, as interpreted according to the principles of patentlaw including the doctrine of equivalents.

The invention claimed is:
 1. A wall fastener assembly for a wall systemcomprising: a fastener having a shaft and a head, said fastenerconfigured to be secured to the said wall system; a washer having anupper surface and a lower surface and a hole extending through saidwasher from the upper surface to the lower surface, wherein said hole isconfigured for receiving said fastener; an elongated, semi-rigid sealmember having a first end and a second end opposite said first end,wherein said seal member includes a center bore that extends along alength of said seal member and is configured for receiving said shaft ofsaid fastener; wherein said wall system comprises an insulation layerand a barrier layer, and wherein when said fastener is secured to saidwall system the seal member extends through the insulation layer withthe first end of said seal member compressed against the barrier layerto form a first seal at the barrier layer and the opposite second end ofsaid seal member is compressed against the lower surface of the washerto form a second seal at the washer to thereby seal the wall fastenerassembly against said wall system, and with the lower surface of thewasher further disposed against an outer surface of the insulation layerabout the seal member.
 2. The wall fastener assembly of claim 1, whereinthe barrier layer comprises at least one chosen from a vapor barrier, afluid barrier, and a weather barrier.
 3. The wall fastener assembly ofclaim 1, wherein said length of said seal member is approximately equalto a thickness of the layer of insulation.
 4. The wall fastener assemblyof claim 1, wherein said washer comprises a portion comprising said holeconfigured for receiving said head of said fastener when said fasteneris installed to the wall system, and wherein said head of said fastenerseals against said portion of said washer.
 5. The wall system fastenerof claim 1, wherein said seal member is tubular and is unitarily formedof a non-metallic material.
 6. The wall fastener assembly of claim 5,wherein said seal member further comprises at least one outwardlyextending rib arranged along the length of said seal member.
 7. The wallfastener assembly of claim 1, wherein said second end of said sealmember comprises either a funnel or a flanged shaped end, and/or whereinsaid first end comprises a pointed end.
 8. The wall fastener assembly ofclaim 1, wherein said fastener comprises a threaded screw.
 9. The wallfastener assembly of claim 1, wherein the washer comprises anon-metallic washer.
 10. The wall fastener assembly of claim 1, whereinthe washer comprises a metallic washer.
 11. The wall fastener assemblyof claim 1, wherein said head of said fastener is compressed against theupper surface of said washer to form a seal at said washer.
 12. The wallfastener assembly of claim 1, wherein said wall system further comprisesa wall board over which the barrier layer is disposed, and wherein thefastener penetrates the wall board.
 13. The wall fastener assembly ofclaim 12, wherein said wall system further comprises a structuralsubstrate over which the wall board is disposed, and wherein thefastener penetrates the structural substrate.
 14. A wall fastenerassembly for a wall system configured for retaining a masonry veneercomprising: a fastener having a shaft and a head, said fastenerconfigured to be secured to said wall system; an elongated, tubularshank configured to provide a space between the masonry veneer and aninner wall of said wall system, wherein said shank defines a center boreextending along the length of said shank and configured for receivingsaid fastener, and wherein said shank includes a pair of flanges thatare spaced apart to form a groove there between; and a washer having anupper surface and a lower surface and a central portion comprising ahole configured for receiving said shank, wherein said central portionis configured for engaging with one of said pair of flanges when saidscrew is installed into said wall system; and an elongated, semi-rigidseal member having a first end and a second end opposite said first end,wherein said seal member includes a center bore that extends along alength of said seal member, and wherein said seal member is configuredfor receiving said shank; and wherein said wall system comprises aninsulation layer and a barrier layer disposed over the inner wall, andwherein when said fastener is secured to said wall system the sealmember extends through the insulation layer with the first end of saidseal member compressed against the barrier layer to form a first seal atthe barrier layer and the opposite second end of said seal member iscompressed against the lower surface of the washer to form a second sealat the washer to thereby seal the wall fastener assembly against saidwall system, and with the lower surface of the washer further disposedagainst an outer surface of the insulation layer about the seal member,and wherein the groove is positioned adjacent the upper surface of thewasher.
 15. The wall fastener system of claim 14, wherein said barrierlayer comprises at least one of a vapor barrier, a fluid barrier, and aweather barrier.
 16. The wall fastener assembly of claim 14, wherein alength of said shank is selected according to a thickness of the layerof insulation.
 17. The wall fastener assembly of claim 14, wherein thelength of said seal member is approximately equal to the thickness ofthe layer of insulation.
 18. The wall fastener assembly of claim 14,wherein the inner wall comprises a wall board and wherein a selectedlength of said shank is selected according to a combined thickness ofthe layer of insulation and the wall board disposed behind theinsulation, wherein said shank is configured to pass through theinsulation and the wall board.
 19. The wall fastener assembly of claim18, wherein a selected length of said seal member is substantially equalto the length of said shank minus the thickness of the wall board, suchthat when said shank passes through the wall board, said seal membercompresses against the barrier layer disposed over the wall board. 20.The wall fastener assembly of claim 14, further comprising a wire tiecomprising a narrow portion configured to be retained by said groove,wherein said wire tie is configured for inserting between rows ofmasonry of the masonry veneer.